ls-prepost® metal forming simulation€¦ · note: ls-prepost 2.4 dated april 14th, 2009 and later...
TRANSCRIPT
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LS-PREPOST METAL FORMING APPLICATION TUTORIAL MANUAL
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LIVERMORE SOFTWARE TECHNOLOGY CORPORATION
LS-PrePost®
Metal Forming Simulation −−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
Tutorial Manual – Trimming and Springback
Version 1.0
April 2009
Copyright © 2009
LIVERMORE SOFTWARE TECHNOLOGY CORPORATION
All Rights Reserved
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DISCLAIMER
THE INFORMATION IN THIS TUTORIAL ARE FOR ILLUSTRATION PURPOSE ONLY AND ARE NOT INTENDED TO BE EXHAUSTIVE OR ALL-INCLUSIVE, THE LS-DYNA KEYWORD FILES PRODUCED BY LS-PREPOST MAY NOT BE EXHAUSTIVE OR APPLICABLE FOR ALL ENGINEERING PROBLEMS, LSTC ASSUMES NO LIABILITY OR RESPONSIBILITY FOR ANY INACCURACY OR DIRECT OR INDIRECT DAMAGES RESULTED FROM THE USE OF THIS DOCUMENTATION AND SOFTWARE.
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Table of Contents
Tutorial #T1 – Trimming of a decklid inner drawn panel .......................................................................... 4
Tutorial #S1 – Springback of a decklid inner trimmed panel ................................................................... 16
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Tutorial #T1 – Trimming of a decklid inner drawn panel
Interface Used: Applications > Metal Forming Files required: drawn.dynain.k (drawn part results) mat_decklid.k (blank material properties) trim.iges
Step 1 Note: LS-PrePost 2.4 dated April 14th, 2009 and later must be used for this tutorial. This tutorial focuses on the set-up process of drawn panel trimming simulation using the Metal Forming interface. 1. Load drawn part results and open Metal Forming Interface launch LS-PrePost File → Open → LS-Dyna Keyword open “drawn.dynain.k” File → Open → IGES File open ‘trim.iges’ Shown in Figure 1 are drawn panel shape superimposed with trim curves, and drawn panel outline superimposed with trim curves. Application → Metal Forming (or hit F11)
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Figure 1
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Step 2 2. Define Blank (refer to Figures 2 and 3) click Blank in the side panel in Figure 2 (launches Blank Assignment Dialog in Figure 3) select “5 Shell” from the right hand list
click
select Element Formulation: 2:Belytschko-Tsay
(Note: To limit the file size in this tutorial, “2:Belytschko-Tsay” is selected here; however, choose
16:Fully Integrated Shell for draw and trimming simulation that also require a subsequent springback
simulation)
enter Number of Integration: 5
(Note: To limit the file size in this tutorial, NIP of “5” is selected here; however, choose at least “7” NIP
for draw and trimming simulation that also require a subsequent springback simulation)
enter Thickness: 0.9; must hit a carriage return.
click MD (launches Material Database Dialog shown in Figure 4)
Figure 2
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Figure 3
6 0.9
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2 3
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Step 3 3. Load material property for the blank (refer to Figure 4)
click to go to current working directory (Figure 4) click “mat_decklid.k” click Preview click OK click Done (Figure 5)
Figure 4
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Step 4 4. Define Process (refer to Figures 5 through 7) click Process in the side panel in Figure 5 (launches Metal Forming Process Dialog box as shown in Figure 6) select Process Type: Trimming (Figure 6)
activate Trimline type: 3D
activate: pick seed node
pick a node which will not be trimmed away
click: Create
click: All
click
click Control Tab (Figure 7)
click (launches Dyna Input Decks Trimming Dialog in Figure 8)
Figure 5
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Figure 6
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Figure 7
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Step 5
5. Define Output Options (Figures 8 and 9)
click (Figure 8)
set Blank File name: blank.k (Figure 9); hit a carriage return.
Set Dyna Input File name: sim.dyn; hit a carriage return.
click
Figure 8
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Figure 9
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Step 6
6. Output LS-Dyna input decks (Figures 10) In Dyna Input Decks (Trimming) Dialog click Browse to specify a file folder for output files
click
Figure 10
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Step 7
7. Run LS-DYNA and processing results Run LS-DYNA - C:\LSDYNA\program\ls971_s_R4.2_winx64_p.exe i=trim.dyn ncpu=2 memory=200M The simulation takes about 28 seconds on a Xeon CPU 5150 @ 2.66GHz. The actual memory used was around 20 MW (million words), about 80 MB (megabytes). Launch LS-PrePost File → Open → LS-Dyna Binary Plot Open “d3plot”
click to move to the last state (Figure 10)
Shown in Figure 11 is the trimmed panel shape.
Figure 10
Figure 11
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Tutorial #S1 – Springback of a decklid inner trimmed panel
Interface Used: Applications > Metal Forming Files required: trimmed.dynain.k (trimmed part results) mat_decklid.k (blank material properties)
Step 1 Note: LS-PrePost 2.4 dated April 14th, 2009 and later must be used for this tutorial. This tutorial focuses on the set-up process of springback simulation using the Metal Forming interface. 1. Load trimmed part results and open Metal Forming Interface launch LS-PrePost File → Open → LS-Dyna Keyword open “trimmed.dynain.k” Shown in Figure 1 is the trimmed panel shape. Application → Metal Forming (or hit F11)
Figure 1
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Step 2 2. Define Blank (refer to Figures 2 and 3) click Blank in the side panel in Figure 2 (launches Blank Assignment Dialog in Figure 3) select “5 Shell” from the right hand list
click
select Element Formulation: 2:Belytschko-Tsay
(Note: To limit the file size in this tutorial, “2:Belytschko-Tsay” is selected here; however, always
choose 16:Fully Integrated Shell for springback simulation as well as the preceding draw and trimming
simulation)
enter Number of Integration: 5
(Note: To limit the file size in this tutorial, NIP of “5” is selected here; however, always choose at least
“7” NIP for springback simulation as well as the preceding draw and trimming simulation)
enter Thickness: 0.9; must hit a carriage return.
click MD (launches Material Database Dialog shown in Figure 4)
Figure 2
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Figure 3
6 0.9
5
7
2 3
4
12
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Step 3 3. Load material property for the blank (refer to Figure 4)
click to go to current working directory (Figure 4) click “mat_decklid.k” click Preview click OK click Done (Figure 5)
Figure 4
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Step 4 4. Define Process (refer to Figures 5 through 9) click Process in the side panel in Figure 5 (launches Metal Forming Process Dialog box as shown in
Figure 7)
click to position the trimmed panel in top view (Figure 5)
select Process Type: Springback (Figure 7)
click Definition tab
activate
click click left mouse button to pick three nodes in the sequence shown (Figure 8) (Note: Three constrained nodes should form a right triangle, with 2nd node along the x-axis) click right mouse button to return to Metal Forming Process Dialog box highlight three nodes in the box to show nodal locations on the panel in the main graphics window click Control Tab
click (Figure 9)
click
click
click (launches Dyna Input Decks Springback Dialog in Figure 10)
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Figure 5
Figure 6
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Figure 7
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Figure 8
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Figure 9
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Step 5
5. Define Output Options (Figures 10 and 11)
click (Figure 10)
set Blank File name: blank.k (Figure 11); hit a carriage return.
Set Dyna Input File name: spbk.dyn; hit a carriage return.
click
Figure 10
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Figure 11
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Step 6
6. Output LS-Dyna input decks (Figures 12) In Dyna Input Decks (SpringBack) Dialog click Browse to specify a file folder for output files
click
Figure 12
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Step 7
7. Run LS-DYNA and processing results Run LS-DYNA - C:\LSDYNA\program\ls971_d_R4.2_winx64_p.exe i=spbk.dyn ncpu=2 memory=160M The simulation takes about 11 minutes on a Xeon CPU 5150 @ 2.66GHz. The actual memory used was around 83 MW (million words), about 640 MB (megabytes). Launch LS-PrePost File → Open → LS-Dyna Binary Plot Open “d3plot”
click to move to the last state (Figure 13)
Shown in Figure 14 is the sprungback panel shape.
Figure 13
Figure 14
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1) Springback displacement contour plot click , Figure 15
click
highlight: Z-displacement
shown in Figure 16 is the springback contour in Z-direction
highlight: resultant displacement
shown in Figure 17 is the resultant springback contour
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Figure 15
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Figure 16
Figure 17